Minimally-invasive heart valves with wireforms

ABSTRACT

Expandable heart valves for minimally invasive valve replacement surgeries are disclosed. In a first embodiment, an expandable pre-assembled heart valve includes a plastically-expandable annular base having plurality of upstanding commissure posts. A tubular flexible member including a prosthetic section and a fabric section is provided, with the prosthetic section being connected to the commissure posts and defining leaflets therebetween, and the fabric section being attached to the annular base. In a second embodiment, an expandable heart valve includes an annular tissue-engaging base and a subassembly having an elastic wireform and a plurality of leaflets connected thereto. The annular base and subassembly are separately stored and connected just prior to delivery to the host annulus. Preferably, the leaflet subassembly is stored in its relaxed configuration to avoid deformation of the leaflets. The expandable heart valves maybe implanted using a balloon catheter. Preferably, the leaflets of the heart valves are secured to the commissure regions of the expandable stents using a clamping arrangement to reduce stress.

RELATED APPLICATIONS

[0001] The present application claims priority from U.S. applicationSer. No. 10/185,812, filed Jun. 28, 2002, which claims priority fromU.S. application Ser. No. 09/549,413, filed Apr. 6, 2000, and now issuedas U.S. Pat. No. 6,454,799.

FIELD OF THE INVENTION

[0002] The present invention relates generally to medical devices andparticularly to expandable heart valve prostheses especially for use inminimally-invasive surgeries.

BACKGROUND OF THE INVENTION

[0003] Prosthetic heart valves are used to replace damaged or diseasedheart valves. In vertebrate animals, the heart is a hollow muscularorgan having four pumping chambers: the left and right atria and theleft and right ventricles, each provided with its own one-way valve. Thenatural heart valves are identified as the aortic, mitral (or bicuspid),tricuspid and pulmonary valves. Prosthetic heart valves can be used toreplace any of these naturally occurring valves, although repair orreplacement of the aortic or mitral valves is most common because theyreside in the left side of the heart where pressures are the greatest.

[0004] Where replacement of a heart valve is indicated, thedysfunctional valve is typically cut out and replaced with either amechanical valve, or a tissue valve. Tissue valves are often preferredover mechanical valves because they typically do not require long-termtreatment with anticoagulants. The most common tissue valves areconstructed with whole porcine (pig)-valves, or with separate leafletscut from bovine (cow) pericardium. Although so-called stentless valves,comprising a section of porcine aorta along with the valve, areavailable, the most widely used valves include some form of stent orsynthetic leaflet support. Typically, a wireform having alternatingarcuate cusps and upstanding commissures supports the leaflets withinthe valve, in combination with an annular stent and a sewing ring. Thealternating cusps and commissures mimic the natural contour of leafletattachment. Importantly, the wireform provides continuous support foreach leaflet along the cusp region so as to better simulate the naturalsupport structure.

[0005] A conventional heart valve replacement surgery involves accessingthe heart in the patient's thoracic cavity through a longitudinalincision in the chest. For example, a median stemotomy requires cuttingthrough the sternum and forcing the two opposing halves of the rib cageto be spread apart, allowing access to the thoracic cavity and heartwithin. The patient is then placed on cardiopulmonary bypass whichinvolves stopping the heart to permit access to the internal chambers.Such open heart surgery is particularly invasive and involves a lengthyand difficult recovery period.

[0006] Recently, a great amount of research has been done to reduce thetrauma and risk associated with conventional open heart valvereplacement surgery. In particular, the field of minimally invasivesurgery (MIS) has exploded since the early to mid-1990s, with devicesnow being available to enable valve replacements without opening thechest cavity. MIS heart valve replacement surgery still requires bypass,but the excision of the native valve and implantation of the prostheticvalve are accomplished via elongated tubes or cannulas, with the help ofendoscopes and other such visualization techniques.

[0007] Some examples of MIS heart valves are shown in U.S. Pat. No.5,980,570 to Simpson, U.S. Pat. No. 5,984,959 to Robertson, et al., andPCT Publication No. WO 99/334142 to Vesely. Although these and othersuch devices provide various ways for collapsing, delivering, and thenexpanding a “heart valve” per se, none of them disclose an optimumstructure for tissue valves. For instance, the publication to Veselyshows a tissue leaflet structure of the prior art in FIG. 1, and anexpandable inner frame of the invention having stent posts in FIGS.3A-3C. The leaflets are “mounted to the stent posts 22 in a mannersimilar to that shown in FIG. 1.” Such a general disclosure stops shortof explaining how to construct an optimum valve. In particular, themeans of attaching the leaflets to the MIS stent is critical to ensurethe integrity and durability of the valve once implanted. All of theprior art MIS valves fall short in this regard.

[0008] In view of the foregoing, it is evident that an improved sewingring that addresses the apparent deficiencies in existing expandableheart valves is necessary and desired.

SUMMARY OF THE INVENTION

[0009] The present invention provides an expandable prosthetic heartvalve for placement in a host heart valve annulus, comprising anexpandable stent system adapted to be delivered in a collapsed state toan implantation site and expanded, and a plurality of prostheticleaflets attached to the stent system. Each leaflet has an approximatelysemi-circular cusp edge terminating at each end in commissure portions,and a coapting edge extending between the commissure portions. Eachleaflet is attached to the stent system substantially entirely along thecusp edge and at both commissure portions, with a coapting edgeremaining unattached. The stent system may comprise an expandablegenerally annular tissue-engaging base and an elastic generally annularwireform attached thereto. The base is adapted to be delivered in aradially collapsed state and expanded into contact with the hostannulus. The annular wireform defines a plurality of upstandingcommissures and a plurality of arcuate cusps between adjacentcommissures, and the prosthetic leaflets are attached to the wireformalong the cusps and commissures, wherein the wireform and leaflets areconfigured to be radially compressed.

[0010] In one embodiment, the heart valve includes a plurality ofupstanding posts attached to one of the tissue-engaging base and elasticwireform, each post having a connector. A plurality of mating connectorsare provided on the other of the tissue-engaging base and elasticwireform for mating with the post connectors. The posts and matingconnectors may be provided for each commissure and each cusp of theelastic wireform so that the valve includes a number of posts and matingconnectors equal to the number of commissures plus the number of cusps.Further, the expandable stent system may include an undulating wireformdefining a plurality of commissures and a plurality of cusps betweenadjacent commissures. The cusp edge of each of the prosthetic leafletsattaches along a wireform cusp, and the commissure portions of eachleaflet terminate in outwardly extending tabs that each attach to awireform commissure, wherein tabs from adjacent leaflets are attachedtogether at each of the wireform commissures.

[0011] In another aspect of the invention, an expandable prostheticheart valve for placement in a host heart valve annulus is provided. Theheart valve comprises an expandable stent portion and an elastic leafletportion connectable to the stent portion. The stent portion defines aninflow end of the valve and is adapted to be delivered in a collapsedstate and expanded into contact with the host annulus. The leafletportion forms a one-way flow occluder on an outflow end of the valve andincludes an elastic wireform defining alternating cusps and commissuresand prosthetic tissue attached substantially entirely therealong. Thestent portion desirably includes a tubular member and a plurality ofconnectors, and wherein a plurality of connectors are provided on theelastic wireform for mating with the tubular member connectors. Thewireform connectors may be provided on each commissure and on each cuspof the wireform so that the valve includes a number of mating connectorsequal to the number of commissures plus the number of cusps. In apreferred embodiment, the prosthetic tissue comprises a plurality ofindividual leaflets secured along the alternating cusps and commissuresof the elastic wireform. Additionally, the wireform may have a fabriccovering, wherein the individual leaflets are stitched along the fabriccovering. The fabric covering continues toward an inflow end of thevalve in a skirt that surrounds the stent portion and is adapted to becaptured between the expanded stent portion and the host annulus. Aplurality of posts rigidly may connect to the stent portion and extendupward within the skirt into mating connection with the elasticwireform.

[0012] In a still further aspect, the present invention provides atwo-part expandable prosthetic heart valve for placement in a host heartvalve annulus, comprising:

[0013] a leaflet subassembly having a wireform defining a plurality ofupstanding commissures and a plurality of arcuate cusps extendingbetween adjacent commissures, a midpoint of each cusp being locatedapproximately equidistant from the adjacent commissures;

[0014] a generally annular tissue-engaging base defining an axis; and

[0015] a system for connecting the leaflet subassembly and thetissue-engaging base, including a plurality of mating connectors on theleaflet subassembly and on the tissue-engaging base, wherein oneconnector each is provided at each commissure, and one at each cuspmidpoint.

[0016] In the two-part heart valve, the tissue-engaging base preferablycomprises an expandable tubular member that is deliverable to the hostannulus in a collapsed state and expandable into contact with the hostannulus to secure the valve therein. Furthermore, the tissue-engagingbase forms an inflow end of the valve, and the system for connecting theleaflet subassembly and tissue-engaging base includes a plurality ofposts coupled to the tubular member and having varying lengths extendingaway from the inflow end of the valve. A first plurality of posts eachhaving a first length connects with the wireform commissures, and asecond plurality of posts each having a second length connects with thewireform cusps shorter than the first length. The mating connectors maybe configured to be joined together by axial compression, preferablywith a snap-fit configuration.

[0017] A further aspect of the invention includes a prosthetic heartvalve having a support stent and a flexible tubular member. The supportstent includes a tubular base along an inflow end a plurality ofgenerally axially-extending commissure posts disposed evenly around thetubular base on an outflow end thereof. The flexible tubular member hasa prosthetic section attached to the commissure posts so as to define aplurality of the prosthetic valve leaflets between the posts, and afabric section connected to the base. The prosthetic section and fabricsection are desirably both generally tubular and attached together at aseam, wherein the seam is spaced from the outflow end of the tubularbase so that only the fabric section of the flexible tubular membercontacts the tubular base. The commissure posts each may have an axialslot, wherein the tubular member is primarily located within the postsexcept for a plurality of loops that extend outward through each slot oneach post. A plurality of inserts sized larger than the slots may beprovided, each of which insert is captured within a loop extendingoutward through each slot to retain the loop through the slot. In apreferred embodiment, the commissure posts are integrally formed withthe base, the base and commissure posts being initially formed from aflat section of material, wherein the commissure posts initially extendfrom the inflow end of the base and are bent 180° to extend alongsidethe base and project beyond the base at the outflow end thereof.

[0018] A prosthetic heart valve of the present invention has a supportstent including a tubular base along an inflow end. A plurality ofgenerally axially-extending commissure posts each having an axial slotis disposed evenly around the tubular base on an outflow end thereof. Aflexible tubular member having an outflow edge is primarily locatedwithin the posts except for a plurality of loops that extend outwardthrough each slot on each post. Further, a plurality of inserts sizedlarger than the slots are provided, each of which insert is capturedwithin a loop extending outward through each slot to retain the loopthrough the slot, the outflow edge of the tubular member defining aplurality of valve leaflets. The tubular base may beplastically-expandable from a first size adapted for minimally invasivedelivery, to a second, functional size that fits within a heart valveannulus.

[0019] A method of minimally-invasive heart valve replacement surgery ona patient is also provided by the present invention. The method includesthe steps of:

[0020] providing an annular tissue-engaging base, the base beingexpandable from a collapsed state;

[0021] providing a generally annular elastic wireform subassembly havinga plurality of prosthetic leaflets connected thereto, the elasticwireform subassembly having a relaxed, expanded size and a compressed,reduced size;

[0022] connecting the wireform and leaflets to the base to form a heartvalve;

[0023] delivering the heart valve with the connected base in itscollapsed state and wireform subassembly in its reduced size to anannulus of the patient's heart valve being replaced; and

[0024] expanding the base into its expanded state in contact with theannulus.

[0025] The step of delivering the heart valve to the annulus may beaccomplished by passing the valve through the patient's vasculature orvia a minimally-invasive port in the patient's chest. Thetissue-engaging base may plastically-expandable from its collapsed stateto its expanded state, and the step of expanding theplastically-expandable base comprises inflating a balloon within theannular base.

[0026] A further understanding of the nature and advantages of theinvention will become apparent by reference to the remaining portions ofthe specification and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0027]FIG. 1 is an exploded perspective view of a first embodiment of anexpandable heart valve of the present invention, including a supportstent and a flexible tubular member;

[0028]FIG. 2 is an assembled perspective view of the expandable heartvalve of FIG. 1;

[0029]FIG. 3 is a longitudinal cross-sectional view taken along line 3-3through a commissure of the expandable heart valve of FIG. 2;

[0030]FIG. 4 is a transverse cross-sectional view taken along line 4-4through the commissure of the expandable heart valve of FIG. 2;

[0031]FIG. 5 is a top plan view of the expandable heart valve of FIG. 2;

[0032]FIG. 6 is an exploded perspective view of a second embodiment ofan expandable heart valve of present invention having two detachablecomponents designed to be assembled post-storage, including atissue-engaging base and a wireform-supported leaflet subassembly;

[0033]FIG. 7 is an assembled perspective view of the expandable heartvalve of FIG. 6, with a fabric skirt removed to illustrate details of aconnecting system between the base and leaflet subassembly;

[0034]FIG. 8 is a plan view of an insert used to both attach individualleaflets to commissures of the wireform, and connect the commissures ofthe leaflet subassembly to the tissue-engaging base of the expandableheart valve of FIG. 6;

[0035]FIG. 9 is a plan view of an individual leaflet for use in theexpandable heart valve of FIG. 6;

[0036]FIG. 10 is a longitudinal cross-sectional view taken along line10-10 of FIG. 7;

[0037]FIG. 11 is a transverse cross-sectional view taken along line11-11 of FIG. 7;

[0038]FIG. 12 is a longitudinal cross-sectional view taken along line12-12 of FIG. 7;

[0039]FIG. 13 is a top plan view of the expandable heart valve takenalong line 13-13 of FIG. 7;

[0040]FIG. 14 is an enlarged perspective view of a commissure region ofthe expandable heart valve taken within the circle 14 of FIG. 7;

[0041]FIG. 15 is an enlarged plan view of the commissure region of theexpandable heart valve taken within the circle 15 of FIG. 13; and

[0042] FIGS. 16A-C illustrate a heart in section and several steps in adelivery and implantation procedure of the expandable valve of thepresent invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0043] The present invention discloses two different expandable heartvalves for implantation in a host annulus, or host tissue adjacent theannulus. The valves may be implanted in any of the four valve positionswithin the heart, but are more likely to be used in replacing the aorticvalve because of the circular shape of the annulus.

[0044] It should also be noted that the specific constructional details,including materials and shapes, may be varied from those shown. Forexample, an expandable tubular base is used in both valve embodiments,and is described as being a plastically-expandable structure thatradially expands into contact with the annulus tissue. Alternatively,the tubular base may be elastically- or self-expandable, or expandableon the application of heat (i.e., using shape memory material). Further,various means are known for plastically or elastically expandingstructures into contact with anatomical passageways, and though thepresent invention illustrates and describes only one such structure,others may be used to practice the invention. For example, anyplastically- or elastically-expandable structure may be modified so asto have a suitable diameter for heart valves and used to practice thepresent invention. In addition, barbs, flanges, staples, and the likemay be added to the tubular base for the purpose of greater attachmentto the host tissue. In short, the present invention should not beconstrued to be limited to the particular structures and materialsdisclosed, the scope of the invention being solely defined by theappended claims.

[0045] With reference to FIGS. 1-5, a first embodiment of an expandableprosthetic heart valve 20 is shown and described. The prosthetic heartvalve 20 is assembled prior to storage. In a second embodiment, shown inFIGS. 6-15, a second embodiment of an expandable heart valve is shownand described. Detachable components of the expandable heart valve inthe second embodiment are separately stored, and assembled just prior toinsertion and delivery to the host annulus, which provides certainadvantages to be described.

[0046] Pre-Assembled Expandable Heart Valve

[0047]FIG. 1 illustrates the first embodiment of the expandable heartvalve 20 exploded, with a flexible tubular member 22 separated from asupport stent 24 along a central axis 26. FIG. 2 illustrates theflexible tubular member 22 attached to the support stent 24 to form theassembled heart valve 20. The heart valve 20 has an inflow end 28 (thelower end in the figure) and an outflow end 30 (the upper end in thefigure).

[0048] The flexible tubular member 22 comprises a leaflet section 32connected to a fabric section 34 at a seam 36. As illustrated, both theleaflet section 32 and fabric section 34 are desirably formed as tubes,such that the seam 36 defines a circle therebetween. Alternatively, theseam 36 may be other than circular if areas of the leaflet section 32 orfabric section 34 need to be expanded around their circumferentialjuncture. For example, the fabric section 34 may need to be increased inthe commissure region of the valve 20, such as indicated by the dashedline 38 in FIG. 1. Whatever the configuration, the fabric section 34 hasa minimum axial height indicated at A.

[0049] Desirably, the leaflet section 32 is formed from pericardialtissue, such as bovine or equine pericardium, suitably treated to renderit biocompatible. Of course, any suitable leaflet material, includingsynthetics, may be used. The fabric section 34 is desirably a wovenpolyester, such as polyethylene terepthalate. Alternatively, the fabricsection 34 may be formed of polytetrafluoroethylene (PTFE), or othersuitable biocompatible sheet material. Still further, the leafletsection 34 may extend the entire axial height of the flexible tubularmember 22, with the fabric section 34 being wrapped around and attachedto the inflow end.

[0050] As seen in FIG. 1, the support stent 24 comprises a tubular base40 and a plurality of upstanding commissure posts 42 distributed evenlyaround the periphery thereof. That is, the tubular base 40 is providedat the inflow end 28 of the support stent 24, with the commissure posts42 extending in the outflow direction. Desirably, there are three suchcommissure posts 42 disposed at 120° intervals about the circumferenceof the stent 24. The tubular base 40 has an axial height indicated at B,which height is less than the axial height A of the fabric section 34 ofthe flexible tubular member 22. The commissure posts 42 extending upwarda sufficient distance such that the entire axial dimension of thesupport stent 24 is slightly greater than the axial dimension of theflexible tubular member 22, as indicated in the assembled view of FIG.2.

[0051] The tubular base 40 comprises a plastically-expandable materialthat can be expanded into the configuration shown in the figures from aradially compressed configuration (not shown). In this regard, theillustrated tubular base 40 essentially comprises a non-self expandingstent that can be expanded from its compressed state using a ballooninflated from within the base, for example. Numerous configurations ofsuch plastically-expandable tubes are available in the prior art, and asmentioned above, the present invention should not be considered limitedto any one configuration. Moreover, in other configurations the base 40may be self- or heat-expandable.

[0052] With reference to FIG. 1, each commissure post 42 attaches to orextends from an inflow rim 44 of the tubular base 40, continuing on theoutside of the tubular base toward the outflow end in an elongatedaxially-extending lower section 46, and terminating in an axiallyextending upper section 48. The upper section 48 commences at apredetermined distance above an outflow rim 50 of the tubular base 40and is stepped radially inward from the lower section 46 at a transitionregion 52. An axial slot 54 is provided in the upper section 48 and inthe transition region 52. The width of the axial slot 54 is desirablyconstant in the upper section 48, but increases at a relief region 56 inthe transition region 52.

[0053] In a preferred embodiment, the commissure posts 42 are formed ofa biocompatible, elastic material, preferably metallic. For example,each commissure post 42 may be formed of stainless-steel, titanium, orElgiloy. Alternatively, the commissure posts 42 may be a biocompatiblepolymer, such as Delrin or polyacetyl.

[0054] In a preferred embodiment, the support stent 24 is formed from asingle piece of flat material. Specifically, the tubular base 40initially comprises a flat, narrow strip of uniform width material withthe commissure posts 42 extending from one long side thereof. Usingconventional means, the narrow strip of material is then rolled into thetubular shape shown in the figures, and the juxtaposed narrow endsjoined by, for example, crimping. Each of the commissure posts 42 isthen bent 180° outward to project in the opposite direction from theiroriginal direction. FIG. 1 illustrates such a configuration in which a180° bend 60 joins each commissure post 42 to the inflow rim 44. Theradius of the bend 60 is such that a narrow space 62 is defined betweenthe lower section 46 of each commissure post 42 and the exterior of thetubular base 40.

[0055] The flexible tubular member 22 attaches to the support stent 24as seen in FIG. 2, with the leaflet section 32 connected to thecommissure posts 42, and the fabric section 34 connected to the tubularbase 40. More specifically, the fabric section 34 surrounds the tubularbase 40 and extends toward the inflow rim 44 in the spaces 62 createdinboard of each commissure post 42. Although not shown, the fabricsection 34 may be attached to the exterior of the tubular base 40, suchas by sutures passed through the fabric and through openings in thetubular base. Because the axial dimension A of the fabric section 34 isgreater than the axial dimension B of the tubular base 40, the seam 36is disposed above the outflow rim 50 (FIG. 1) of the base. This is moreclearly shown in the cross-section of FIG. 3.

[0056] The leaflet section 32 is disposed substantially between thecommissure posts 42, except for a number of loops 70 threaded outwardthrough the axial slots 54. As seen FIGS. 2-3, the loops 70 comprisesregions of the tubular leaflet section 32 pinched and threaded throughthe axial slots 54. A plurality of inserts 72 are used to secure theloops 70 to the exterior of the commissure posts 42. That is, as seenFIG. 4, the inserts 72 each have a width W that is greater than thecircumferential width of the axial slots 54. Because the inserts 72 aredisposed within the loops 70, they prevent the loops from pulling inwardagain through the axial slot 54. A plurality of stitches 74 arepreferably provided to secure the leaflet section 32 to the inserts 72.In addition, as seen in FIG. 3, stitching 76 passes through an aperture78 in each insert 72, and through an aperture 80 provided in the outflowend of each commissure post 42. In this manner, each insert 72 issecured with respect to the support stent 24.

[0057] With reference to FIGS. 2 and 5, a plurality of leaflets 82 aredefined between the support stents 24 by the leaflet section 32.Specifically, where there are three stent post 24, a generallytriangular arrangement of leaflets 82 remains unconstrained in themiddle portion of the valve 20 and opens and closes depending on bloodflow forces. Furthermore, the continuous flexible tubular member 22provides a flow channel for blood through the valve 20. When thepressure differential is such that blood flows into the inflow end 28 ofthe valve 20, the leaflets 82 spread apart and the valve opens.Conversely, when the pressure differential reverses, the leaflets 82come together, or coapt, to close the valve 20.

[0058] When the pressures are such that the valve closes, radiallyinward forces are imposed on the free edge of the leaflet section 32,which may tend to cantilever the support stents 24 inward a slightamount. Localized stresses on the leaflet section 32 are reduced at theconnection with the stent supports 24, however, because of the use ofthe inserts 72 within the loops 70. That is, as best seen in FIG. 4,radially inward forces on the leaflets 82 as indicated by the arrow 84,pull the inserts 72 inward such that the leaflet material is clampedbetween each insert and the respective commissure post 42. Althoughstitching 74 through the leaflet section 32 is provided, such stitchingis not subjected to direct tensile stresses, and thus is less likely totear through the leaflet tissue.

[0059] Certain features of the valve 20 reduce wear typically associatedwith stent-leaflet dynamic contact. First, because the axial dimension Aof the fabric section 34 is greater than the dimension B of the tubularbase 40, any contact between the flexible tubular member 22 and thetubular base 40 (at the outflow rim 50) is between fabric and the base.That is, the leaflet section 32 is not placed in contact with the base40, thus increasing the life of the valve. Additionally, the enlargedrelief region 56 of the slot 54 in the transition region 52 helps reducethe rubbing that might otherwise occur between the commissure posts 42and the leaflets 80. That is, the leaflet section 32 continuessubstantially axially downward from the loops 70, as seen in FIG. 3, andthe relief region 56 provides a small gap in the transition region 52between the leaflet tissue and the sides of the slot 54 to help preventrubbing therebetween.

[0060] In use, the assembled heart valve 20 as seen in FIG. 2 isinitially provided in a radially compacted configuration (not shown).Preferably, the valve 20 is loaded about a balloon catheter and within adelivery cannula. The balloon catheter with the valve 20 loaded thereonis then passed through the patient's vasculature (or through an accessport in the chest) into proximity with the host annulus. Alternatively,where the chest of the patient is opened, the reduced size valve 20 isinserted into position using a holder.

[0061] Once in position within the annulus of the valve being replaced,the balloon (or other expanding means) causes the tubular base 40 toexpand into contact with the annulus. Actually, because the commissureposts 42 and fabric section 34 surround tubular base 40, these elementsare compressed against the host annulus. Because the tubular base 40 isplastically-expandable, it substantially retains its expanded shape. Aslight over-expansion of the tubular base 40 may be required tocompensate for any elastic spring-back character of the material used.Again, barbs or staples may also be utilized to further secure the valve20 and in place. Ultimately, the balloon catheter is deflated andremoved from within the valve 20.

[0062] Expandable Heart Valve Assembled Post-Storage

[0063]FIGS. 6-15 illustrate an expandable prosthetic heart valve 100including, as best seen in FIG. 6, a leaflet subassembly 102 adapted toconnect to a tissue-engaging base 104. The two components are both shownin FIG. 6 in their radially expanded configurations, though both aredesigned to be radially compressed and delivered through a catheter orcannula, for example. In contrast with the first embodiment, however,the two components are stored separately, and connected just prior todelivery into the body of the patient. In general, the two componentsprovide a tissue-engagement ring and a relatively more flexible valvemember having fluid occluding surfaces. It should be understood thatconfigurations of these two connectable components other than thosespecifically shown may be encompassed by the appended claims.

[0064] As seen in FIG. 6, the leaflet subassembly 102 comprises anelastic wireform 106 supporting a plurality of prosthetic leaflets 108,and a fabric skirt 110. The wireform 106 comprises a continuousundulating pattern of alternating commissures 112 and cusps 114.Preferably, the valve 100 is a tri-leaflet type, such that the wireform106 has three commissures 112 and three cusps 114, with three leaflets108 support thereby. In particular, each leaflet 108 is desirablyattached to adjacent commissures 112, and along the entire arcuate cusp114 therebetween. As will be described in more detail below, theleaflets 108 each attach to a fabric covering 116 around the wireformcusps 114. In a preferred embodiment, the elastic wireform 106 is formedof a biocompatible, elastic material, preferably metallic. For example,the elastic wireform 106 may be formed of stainless-steel, titanium, orElgiloy. Alternatively, the elastic wireform 106 may be formed from abiocompatible polymer, such as Delrin or polyacetyl. In this sense,therefore, the term “wire” in wireform should not be construed aslimiting the material to metallic.

[0065]FIG. 7 illustrates an assembled valve 100 with the fabric skirt110 shown in FIG. 6 removed for clarity. That is, the fabric skirt 110is sized to drape outside of and surround the tissue-engaging base 104,but is removed in FIG. 7 to show the connection details between the baseand the leaflet subassembly 102. The valve 100 defines an inflow end 120and an outflow end 122.

[0066]FIG. 9 illustrates an exemplary leaflet 108 having an arcuate cuspedge 124 opposite a linear coapting edge 126. The cusp edge 124 isgenerally semi-circular, and terminates at commissure portions 128. Apair of oppositely-directed tabs 130 extend outward from both ends ofthe coapting edge 126, and are seen in FIG. 6 prior to attachment to thewireform 106. That is, the tabs 130 from adjacent leaflets 108 jointogether and pass through the inverted U-shaped commissures 112 of theelastic wireform 106. In a preferred embodiment, each leaflet 108 isformed from pericardial tissue, such as bovine or equine pericardium, ora synthetic material, that has been suitably treated to render itbiocompatible.

[0067] With reference again to FIG. 6, the cusp edge 124 of each leaflet108 is shaped so as to follow a cusp 114 of the elastic wireform 106.The fabric skirt 110 extends to an inflow edge 132 from each of thecusps 114, and when the skirt is assembled to the tissue-engaging base104, the inflow edge extends substantially to the inflow end 120 (FIG.7) of the valve. The fabric skirt 110 further terminates at outflowedges 134 between adjacent wires of the wireform commissures 112, belowthe leaflet tabs 130 extending therethrough. The skirt 110 may be madeof a biocompatible fabric such as polyester, or of other suitablebiocompatible sheet material.

[0068] The leaflet subassembly 102 attaches to the tissue-engaging base104 at discrete locations, securely coupling each of the commissures 112and cusps 114 of the elastic wireform 106 to the base. As seen best inFIG. 6, the tissue-engaging base 104 comprises a tubularplastically-expandable member 140 having an inflow rim 142 and outflowrim 144. A plurality of commissure posts 146 are either rigidly attachedto, or securely coupled to, the tubular member 140 so as to extendgenerally axially beyond the outflow rim 144 in the outflow direction.Likewise, a plurality of cusp posts 148 are rigidly attached to, orsecurely coupled to, the tubular member 140 so as to extend beyond theoutflow rim 144. Because the commissure posts 146 couple to the wireformcommissures 112, they are longer than the cusp posts 148 that couple tothe wireform cusps 114.

[0069] As illustrated, both the commissure posts 146 and cusp posts 148extend through upper and lower sleeves 150 a, 150 b, respectivelyprovided on the exterior of the tubular member 140, and are desirablyaxially secured therein. It should be noted that this is only one ofnumerous possible ways to rigidly couple upstanding posts to aplastically-expandable tubular member. However, the posts 146,148 aredesirably located on the outside of the tubular member 140 so as not tointerfere with a balloon for expanding the tubular member from theinside, nor to interfere with blood flowing through the valve. It shouldalso be noted that in a reverse configuration, the posts 146, 148 may beinitially attached to the wireform commissures 112 and cusps 114,respectively, as part of the leaflet subassembly 102 and subsequentlyconnected to mating structures (not shown) provided on thetissue-engaging base 104.

[0070] A plurality of connectors are provided for attaching the elasticwireform 106 to the posts 146, 148 of the tissue-engaging base 104. Inparticular, as seen in FIG. 6, each commissure post 146 provides a lowercommissure connector 160 thereon. Likewise, each cusp posts 148 providesa lower cusp connector 162. In the illustrate embodiment, the outflowend of each of the posts 146, 148 is bent 90° to face radially inward,and a groove formed therein defines the respective connectors 160,162.

[0071]FIGS. 9-11 illustrate the configuration of the connection betweenthe leaflet subassembly 102 and tissue-engaging base 104 at thecommissures of the valve. With specific reference to FIG. 10, the lowercommissure connector 160 of the commissure post 146 mates with an uppercommissure connector 164 of an insert 166 (isolated in FIG. 8) securedto the wireform commissure 112. As seen in FIG. 11, adjacent leaflets130 extend radially outward between spaced wires of the wireform 106 andwrap around the insert 166 to be connected on an outer side thereof witha plurality of stitches 168. FIG. 8 illustrates one form of the insert166 wherein the upper commissure connector 164 comprises a downwardlyopening partial circle which mates with the groove of the lowercommissure connector 160, as seen in FIG. 10. In this manner, thecommissures 112 are securely fastened with respect to thetissue-engaging base 104 by virtue of the interaction between the lowercommissure connector 160 and upper commissure connector 164.

[0072] With reference again to FIGS. 6 and 7, a plurality of upper cuspconnectors 170 attach to the approximate midpoint of each of the cusps114 of the wireform 106. Each upper cusp connectors 170 is configuredand positioned to mate with the lower cusp connector 162 formed on eachof the cusp posts 140. Again, the upper cusp connector 170 may beprovided with a downwardly opening partial circle that mates with thegroove of the lower cusp connector 162.

[0073] With specific reference to FIG. 12, certain constructionaldetails of the valve cusps are further illustrated. The fabric covering116 of the wireform 106 is shown as a tube having an upper fabricextension 180 and a lower fabric extension 182 sandwiched around aradial portion 184 of the upper cusp connector 170. The upper cuspconnector 170 extends outward and bends 90° downward to mate with thelower cusp connector 162. The upper fabric extension 180 continuesoutward and downward in the fabric skirt 110. The lower fabric extension182 bends 180° underneath the cusp edge 124 of the respective leaflet108. Stitching 186 secures the combined layers of the upper extension180, radial portion 184, first part of the lower extension 182, leafletcusp 124, and wrapped-around portion of the lower extension 182.

[0074] Desirably, both the insert 166 and upper cusp connector 170 aremade from a suture-permeable material having sufficient strength tomaintain the connections between the leaflet subassembly 102 andtissue-engaging base 104. For example, the insert 166 and connector 170may be made of Delrin, or other suitable polymer. As illustrated, eachof the connectors 164 and 170 are partial circles that fit aroundtubular grooves in the respective posts 146,148. Of course, otherarrangements are possible, and the present invention should not beconsidered limited to those connectors illustrated.

[0075] As with the earlier embodiment, the valve 100 utilizes alow-stress connection between the leaflets 108 and the elastic wireform106. In particular, as seen in FIG. 11, the provision of the insert 166provides a clamping force during diastole between the insert and thewireform 106 against the portion of the leaflets 108 therebetween. Thestitching 168 is not subjected to direct tensile stresses, and there isthus less chance for tearing.

[0076] Leaflet subassembly 102 is desirably stored in its expandedstate, as seen in FIG. 6 (which, as mentioned, does not illustrate thecommissure attachment structure). That is, the wireform 106 and leaflets108 may be stored immersed in a preservative such as glutaraldehyde in asterile container until needed. In this regard, the prosthetic leaflets108 remain in their functional shape during storage. This greatlyreduces adverse wrinkling or other permanent or semi-permanent damage tothe leaflets over time, and improves the quality of the valve 100. Atthe same time, the base 104 desirably does not include any bioprostheticor otherwise perishable components, and thus may be stored in a separatedry sterile container. This method also permits the combination ofdifferent bases with any one leaflet subassembly 102, or visa versa. Forexample, the type of attachment mechanism (i.e., staples, barbs,sutures, etc.) of the base 104 to the annulus may be selected by thesurgeon, with different bases being attached in different ways, and allbeing combinable with a particular leaflet subassembly 102. Also, thetype of base may be selected based on patient indications; with aself-expanding base being preferred in some situations and aballoon-expanded base in others.

[0077] In use, the leaflet subassembly 102 is compressed from itsexpanded configuration to a size corresponding to the tissue-engagingbase 104 in its compressed state (not shown). If the tissue-engagingbase 104 is plastically deformable then it is initially supplied in itscompressed state. Alternatively, a self-expandable base 104 will have tobe compressed either before or after connection to the similarlyconfigured leaflet subassembly 102. Compression of the leafletsubassembly 102 (and base if necessary) may be accomplished using atapered mandrel through which the subassembly is passed, or with a cinchor other direct constricting means. The two components are thenconnected together, just prior to insertion into the patient's body, andthe valve 100 delivered simultaneously to the host annulus site. Toconnect the two components, the fabric skirt 110 is passed around theoutside of the commissure posts 146 and around the tubular member 140.Each of the upper connectors 164 and 170 are caused to mate with thelower connectors 160, 162. In the illustrated embodiment, such a matingoperation simply requires forcing each of the partial circles definingthe upper connectors over the grooves defining the lower connectors. Thepartial circles open slightly, but then spring inward when theconnectors snap together and the groove is fully seated.

[0078] There are a number of ways to deliver the valve 100 to the aorticannulus. For one, the tubular member 140 may be mounted around a ballooncatheter and inserted via an introducer or other cannula into thepatient's vasculature and to the aorta. Alternatively, an open-heartprocedure or less-invasive port procedure may be utilized, with thetissue-engaging base 104 being delivered to the host annulus using aholder or other such means.

[0079]FIG. 16A depicts a sectional view of a heart 200 having a leftventricle chamber 202 opening to an ascending aorta 204 through anaortic annulus 206. The ascending aorta 204 continues over an aorticarch 208, and branches off into several upper body arteries 210 beforedescending to the abdominal aorta (not shown). As mentioned above, theexpandable valves of the present invention can be delivered intoproximity of the aortic annulus 206 in several ways, including throughthe patient's vasculature as shown.

[0080] In particular, a valve delivery catheter 212 is shown in thecutaway portion of the ascending aorta 204, having been introduced alongthe direction of the arrow 214 so that a distal end thereof liesadjacent the aortic annulus 206. The catheter 212 can be introducedpercutaneously into the patient's arterial system (e.g. into aperipheral artery such as the femoral artery) and advanced to theascending aorta 204. The catheter shaft preferably has a length of atleast about 80 cm, usually about 90-100 cm, to allow transluminalpositioning of the shaft from the femoral and iliac arteries to theascending aorta. Alternatively, the shaft may have a shorter length,e.g. 20-60 cm, for introduction through the iliac artery, through thebrachial artery, through the carotid or subclavian arteries, or througha penetration in the aorta itself. In the femoral approach, the catheteris long enough and flexible enough to traverse the path through thefemoral artery, iliac artery, descending aorta and aortic arch. At thesame time, the catheter has sufficient pushability to be advanced to theascending aorta by pushing on the proximal end, and has sufficientaxial, bending, and torsional stiffness to allow the physician tocontrol the position of the distal end, even when the catheter is in atortuous vascular structure. Alternatively, the catheter 212 may bepassed through a port between ribs in the patient's thorax above theheart and through an incision in the aortic arch 208, in a so-calledminimally-invasive procedure.

[0081] Techniques for introducing catheters into the human vasculatureare well-known, and typically involve the introduction of a guidewire216 first, followed by an obturator or dilator (not shown) within asheath 218. The dilator facilitates introduction of the catheter sheath218 into the vasculature, and is then removed, though the guidewire 216typically remains in place. Subsequently, a valve of the presentinvention, such as valve 100 seen in FIGS. 6-15, is delivered over theguidewire 216 and to the distal end of the sheath 218. In accordancewith one aspect of the present invention, the valve 100 includes aballoon-expandable portion and thus is mounted over an expansion balloon222. To facilitate passage of the valve 100 through the sheath 218, apusher 224 may be used.

[0082]FIG. 16B illustrates a second step in the exemplary valve deliveryprocedure in which the sheath 218 is retracted in a proximal directionas indicated by arrow 226. Retraction of the sheath 218 exposes thevalve 100, which is positioned within the aortic annulus 206 with theassistance of fluoroscopy and radiopaque markers, ultrasonic imaging, orthe like. If the valve 100 includes self-expanding components,retraction of the sheath 218 releases the outer restraint on the valveand permits it to expand into contact with the annulus 206. In theillustrated embodiment, however, the tubular member 140 of thetissue-engaging base 104 is plastically-deformable and retains itsradially constricted configuration after retraction of the sheath 218.Because of the rigid connections between the leaflet subassembly 102 andthe base 104, the subassembly also remains in its constrictedconfiguration.

[0083] Finally, in FIG. 16C, the balloon 222 is inflated to cause thetissue-engaging base 104 to radially expand into contact with the aorticannulus 206, as indicated by the arrows 230. Simultaneously, the leafletsubassembly 102 radially expands by virtue of the rigid connection withthe base 104, and by virtue of its spring bias. A balloon inflationcatheter 232 is seen projecting from the pusher 224 and through theleaflet subassembly 102. With reference back to FIG. 6, the fabric skirt110 is captured between the tubular member 140 and the surroundingtissue, and is in direct contact therewith. Therefore, by virtue of thecontinuous connection between the cusp edges 124 of the leaflets 108 andthe fabric skirt 110, the skirt forms a flow channel for blood enteringthe inflow end 120 of the valve 100. Again, the plastically-expandabletubular member 140 may be slightly over-expanded to account for anyspring-back in the material. Further, as mentioned above, the tubularmember 140 may include staples or barbs or other such attachmentstructure for securely locating the valve 100 within the annulus 206.

[0084] Once the valve 100 is fully expanded and securely attached to theannulus 206, the balloon 222 is deflated and removed. Such an operationmay include elongating the balloon 222 in the distal direction andreducing its radial dimension by, for example, twisting. Care must betaken so as not to damage the leaflets within the subassembly 102 duringretraction of the balloon 222 therethrough. After the balloon 222 hasbeen retracted within the sheath 218, the entire catheter 212 is removedfrom the patient.

[0085] The fully formed valve 100 has a number of distinct advantagesover prior expandable valves. For example, as mentioned above, theprosthetic leaflets 108 may be stored in the final, uncompressedimplantation shape. This is in contrast to prior expandable valves wherethe entire valve may be initially compressed such that the leaflets arestored in a compressed state. Consequently, valves of the prior art canbe stored for years prior to use, and permanent wrinkling of thecompressed leaflets may be a real problem.

[0086] Furthermore, each of the leaflets 108 is supported substantiallyentirely around the undulating wireform 106, which has proven to provideoptimal valve performance. Also, separate leaflets are used as opposedto a continuous tube, as in the first embodiment. Additionally, theadvantageous low-stress attachment structure of the leaflet tabs 130 tothe wireform commissures 112 further increases the durability of thevalve.

[0087] While the foregoing is a complete description of the preferredembodiments of the invention, various alternatives, modifications, andequivalents may be used. Moreover, it will be obvious that certain othermodifications may be practiced within the scope of the appended claims.

What is claimed is:
 1. A minimally-invasive heart valve for implantationat a host heart valve annulus, comprising: a collapsible and expandableheart valve stent adapted to be delivered in a collapsed state to theheart valve annulus and expanded in position at the annulus, the stentdefining a plurality of upstanding commissures and a plurality ofarcuate cusps, each cusp extending between adjacent commissures; and aplurality of prosthetic leaflets attached to the stent, each leaflethaving an approximately semi-circular cusp edge terminating at each endin commissure portions and a coapting edge extending between thecommissure portions, each leaflet being attached substantially entirelyalong its cusp edge to one of the stent cusps and each leaflet beingattached at its commissure portions to adjacent stent commissures withthe coapting edge remaining unattached.
 2. The heart valve of claim 1,wherein the stent comprises a generally annular elastic wireformoriented around a flow axis with the upstanding commissures projectinggenerally in an outflow direction.
 3. The heart valve of claim 2,further including: an annular tissue-engaging base separate from thewireform and expandable from a collapsed state to an expanded state,wherein the wireform and leaflets are connected to the base.
 4. Theheart valve of claim 3, wherein the tissue-engaging base isplastically-expandable from the collapsed state to the expanded state.5. The heart valve of claim 3, wherein the wireform attaches to the baseat discrete locations so as to couple each of the commissures and cuspsof the elastic wireform to the base.
 6. The heart valve of claim 1,wherein the prosthetic leaflets each have a cusp edge attached along awireform cusp and a pair of commissure portions terminating in outwardlyextending tabs that each attach to a wireform commissure, wherein tabsfrom adjacent leaflets are attached together at each of the wireformcommissures.
 7. The heart valve of claim 6, wherein the tabs fromadjacent leaflets extend outward between spaced wires of the wireformcommissures, and wherein inserts are provided around which the adjacentleaflet tabs wrap and are secured, the inserts being size larger thanthe distance that the wires of the wireform commissures are spaced apartso as to maintain the leaflet tabs on the outside of the wireformcommissures.
 8. The heart valve of claim 1, wherein the prostheticleaflets are formed and attached to the stent separately from eachother.
 9. The heart valve of claim 1, wherein the stent has a fabriccovering and the leaflets attach to the stent by being stitched alongthe fabric covering.
 10. An expandable prosthetic heart valve forplacement in a host heart valve annulus, comprising: a collapsible andexpandable stent system adapted to be delivered in a collapsed state toan implantation site and expanded, the stent system including anexpandable generally annular tissue-engaging base and an elasticgenerally annular wireform attached to the base, the wireform defining aplurality of upstanding commissures and a plurality of arcuate cusps,each cusp extending between adjacent commissures; and a plurality ofprosthetic leaflets attached to the wireform in a manner that providescontinuous support for each leaflet along the wireform cusps.
 11. Theheart valve of claim 10, wherein the tissue-engaging base isplastically-expandable from a collapsed state to an expanded state. 12.The heart valve of claim 10, wherein the wireform attaches to the baseat discrete locations so as to couple each of the commissures and cuspsof the elastic wireform to the base.
 13. The heart valve of claim 10,wherein the commissure portions of the prosthetic leaflets terminate inoutwardly extending tabs that each attach to a wireform commissure,wherein tabs from adjacent leaflets are attached together at each of thewireform commissures.
 14. The heart valve of claim 13, wherein the tabsfrom adjacent leaflets extend outward between spaced wires of thewireform commissures, and wherein inserts are provided around which theadjacent leaflet tabs wrap and are secured, the inserts being sizelarger than the distance that the wires of the wireform commissures arespaced apart so as to maintain the leaflet tabs on the outside of thewireform commissures.
 15. The heart valve of claim 10, wherein theprosthetic leaflets are formed and attached to the wireform separatelyfrom each other.
 16. The heart valve of claim 10, wherein the generallyannular wireform is oriented around a flow axis with the upstandingcommissures projecting generally in an outflow direction and definingthe outflow end of the heart valve.
 17. The heart valve of claim 10,wherein the wireform has a fabric covering and the leaflets attach tothe wireform by being stitched along the fabric covering.